Concrete slab having integral wall base forms and wall base plates for automated construction and system thereof

ABSTRACT

A composite automated building construction system, with automated alignment of various truss and wall sections, includes a wall section having frame, an expanded wallboard, and a concrete layer. The wallboard includes an outer portion and inset portion wherein the wallboard is attached to the frame with the outer portion covering an exterior side of the frame and the inset portion is disposed within the frame. The wallboard thus provides exterior and interior insulation for the system. The concrete layer is sprayed on to the outer portion of said wallboard, forming a strong durable composite construction system. A building is constructed with these wall sections by way of a base form template delimiting the boundary of the building. The base forms are installed and then a concrete foundation slab is poured over the base forms. Pre-installed bolts extend above the concrete foundation to providing pre-determined mounting points for the frames for the wall sections.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/063,765 filed on Oct. 25, 2013, now U.S. Pat. No. 8,739,494,which is a continuation of U.S. patent application Ser. No. 13/597,620filed on Aug. 29, 2012, now U.S. Pat. No. 8,567,153 issued Oct. 29,2013, which is a continuation-in-part of U.S. patent application Ser.No. 13/451,927 filed on Apr. 20, 2012, which claims the benefit of U.S.Provisional Application No. 61/477,677 filed on Apr. 21, 2011.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to systems and methods of building constructionand more particularly to systems and methods including a composite ofconcrete, framing, and other materials and structures.

2. Description of Related Art

Conventional building construction typically comprises three primarysystems and methods: (1) wood stud construction; (2) concrete blockconstruction; and (3) concrete panel construction. Wood studconstruction system requires skilled carpenters to assemble the piecesand cut lumber according to structural drawings that require skilledinterpretation. Concrete block construction, wherein the perimeter of ahousing unit is comprised of arranged cinder blocks or concrete blocksin a structurally sound fashion, is slow to put into place and requiresa large number of skilled masons to carry out effectively. Concretepanel construction, wherein pre-cast panels are put into place againstor in conjunction with a framing system, requires heavy equipment tolift and place the concrete panels, as well as a skilled work force tobuild the structure that provides the framing template for the panels.

Accordingly, the development of better building systems for constructinglow cost, efficient and easily built housing units has been slowed bythe need for skilled labor to assemble the components required for thehousing unit. In many locales, skilled labor is in short supply and/orprohibitively expensive which has restricted the ability to constructlow cost housing units en masse, particularly in underdevelopedcountries. Other problems with present building construction technologyinclude the need to build housing units at a low cost and quickly, theability to build housing units having a resilient construction that doesnot require a great deal of maintenance, is strong structurally, andprovides desired insulation from the elements. Thus, in many countries,the aspirations of having modernized housing units have slowly waned.

Furthermore, present construction methods typically rely on steel studframes having insulation sprayed or placed on the interior side of thestud wall. Such an arrangement is not as efficient as possible becauseheat can be conducted from wall surfaces directly to the frame elements,circumventing the surrounding insulation. Providing external insulation,i.e. insulation placed on the outside of the stud frame can be helpful,but to date there has not been a reliable means to applying suchinsulation. Further, insulation placed only externally will not providesufficient heat and cold protection and therefore spray or rollinsulation will still have to be provided on the inside wall. Thus, theconstruction can be rendered expensive, cumbersome, and labor intensive.

Several attempts have been made at providing cheaper and more efficientconstruction methods, however none have adequately address the need foran easier to assemble yet structurally sound and insulativeconstruction. For example, U.S. Pat. No. 4,751,803 to Zimmermandescribes a construction method wherein precast concrete studs havingprotruding fasteners are used to build the framework of the walls of astructure. The walls are assembled in a horizontal plane and rigid sheetinsulation is attached to concrete studs and wire mesh is laid upon thesheet insulation. Concrete is then poured onto the insulation, the wire,and the protruding fasteners to form a waterproof outer surface. Beamsare bonded to the studs. After construction, the structure can betransported to the construction site and assembled. The patent alsodiscloses a “jig” for assembling the structure. Thus, while providing ameans for prefabricating building walls, Zimmerman relies on the use ofa jig or form mold in which concrete is poured prior to transportationto the construction site. This severely limits the accessibility of theinvention because the relatively heavy poured concrete slabs areexpensive and difficult to transport to remote locations, particularlythose where affordable housing is desired. Further, the complex studframing structure renders the system expensive to manufacture andassemble. Finally, the system does not provide for both internal andexternal insulation of the walls.

U.S. Pat. No. 5,522,194 to Graulich describes a planar building panelcore having two faces coated with a cementitious material whereby thecore is a closed-cell foam insulation board. A metal grid or lath islaid over the foam before the cement is applied. The core panel includesa plurality of spaced metal furring vertical channel members which arefastened to a support structure and a steel reinforcing sheet spanningthe face of each panel, thus comprising a frame surrounding the foaminsulation board. Cement is applied over the metal grid and the foamboard to result in a unitary construction panel. While providing arelatively sound system, this construction invention is flawed in thatthere is no means for prefabricating any aspect of the design and itrequires extensive assembly of the frame elements around the foam boardduring construction of the system. Assembly cannot be complete usingstandard hand tools by unskilled labor. Further, the foam board is notdisposed on the exteriors of the frame and therefore the structuralrigidity and insulative properties are compromised.

Similarly, U.S. Pat. No. 6,519,904 to Phillips describes a verticalreinforced concrete wall having a plurality of insulating panelshorizontally spaced from each other formed of a polystyrene material. Apair of channel-shaped vertical side members are fitted over therespective side edges of the insulating panel during onsiteinstallation. The panels are then mounted between a pair of opposedupper and lower channel-shaped track members which extend horizontallyto define the upper and lowers ends of the vertical wall. A wire mesh isattached to the outside of the side members and horizontal members andconcrete is applied over the wire mesh, insulation board, and framingmembers. Again, the complex framing structure is disposed around thefoamboard and includes numerous interconnected parts which renders thesystem difficult to assemble and not amenable to affordable housingconstruction by unskilled workers. Finally, the construction method doesnot provide both internal and external insulation at the wall surface.

In contrast, the present invention provides an improved buildingconstruction system and method designed to addressed the problemsoutlined above and provides a systemized product that provides housingfor residential or commercial use, can be economically constructed, doesnot need high level and expensive skilled labor, is extremely strong andweather resistant, has excellent internal and external thermalinsulation capabilities, and requires low maintenance. It is, therefore,to the effective resolution of the aforementioned problems andshortcomings of the prior art that the present invention is directed.However, in view of the building construction system and methods inexistence at the time of the present invention, it was not obvious tothose persons of ordinary skill in the pertinent art as to how theidentified needs could be fulfilled in an advantageous manner.

SUMMARY OF THE INVENTION

The present invention provides a composite building construction wallsection, comprising: a frame, wallboard, and a concrete layer. Thewallboard comprises an outer portion and inset portion wherein thewallboard is attached to the frame with the outer portion covering anexterior side of the frame and the inset portion is disposed within theframe. The wallboard thus provides exterior and interior insulation forthe system. The wallboard may be attached to the frame by an adhesive orby common fasteners. The concrete layer is sprayed on to the outerportion of said wallboard, forming a strong durable compositeconstruction wall section.

In some embodiments, one or more rebar supports are attached to theframe at the exterior side of said frame and are spaced apart from thewallboard. The rebar supports are secured to the frame by one or morekey bolts which pass through the wallboard and into the frame and arelockingly engaged with the frame. The frame may include key holes withcorrespond to the lock ends of the key bolts, which bolts may be securedby inserting and rotating them within the frame. A wire grid may beattached to the one or more key bolts and is spaced apart from thewallboard and the rebar supports whereby the grid and the rebar providea support structure for the concrete layer. In some embodiments, theconcrete layer is 3 inches thick.

In some embodiments, the frame includes a plurality of outer framingmembers and one or more cross members. The inset portion of thewallboard includes one or more channels configured to accommodate theone or more cross members of the frame and thus fit snugly inside theframe. In some embodiments, the outer framing members and the one ormore cross members include one or more apertures for the routing ofelectrical wires or plumbing and the apertures are adapted to receiveconduits for protecting the electrical wires and the plumbing. Thewallboard may also include channels to accommodate the conduits. One ormore guide wires may be attached to the frame by key bolts at theexterior side of said frame, the guide wires spaced apart from saidwallboard and adapted to indicate the depth of the concrete layer to beapplied.

In some embodiments, the frame sections are manufactured using acomputer system that prefabricates and codes the frame sections for easyassembly. The interior side of the frames is configured to receivedrywall or other finishing material. In some embodiments, the framecomprises high tensile steel and the wallboard comprises expandedpolystyrene. The wallboard may be dimensioned such that the depth of theinset portion is greater than the depth outer portion of said wallboard.In any event, the wallboard provides significant external and internalinsulation: a substantial advantage over the prior art.

A housing unit or building may be constructed by providing one or moreframe sections each prefabricated and coded according to a buildingplan. The frame sections are assembled together to form a housingstructure. Then the wallboard is attached to the frame sections, therebar supports and wire grid is attached to the wallboard, the guidewire is installed and then concrete is sprayed over the wire grid,rebar, and wallboard until the relatively thick concrete layer isformed. Optionally, the guide wire may be used to indicate the depth ofthe concrete to be applied. Once the concrete has been cured, it can befinished with paint, stucco, or other known housing unit finishmaterials. The interior side of the frame can be finished with drywall.

The structural integrity of the present construction wall section isgreatly enhanced due to the relatively thick concrete layer applied tothe wallboard-frame combination. The completely structure is capable ofwithstanding hurricane force winds, earthquakes, and other weatherconditions whereby the structure exceeds national and local buildingcodes to that effect. The present invention provides a substantialimprovement over the prior art with respect to the simplicity and costof construction, as it does not require skilled laborers such as masons,carpenters, and the like. The prefabrication and coding of the framesections enhances the ease-of-build even more. More importantly, theexpanded wallboard provides both internal and external insulation in asingle easy to assemble piece which also provides a surface for adhesionto the concrete layer. The combined internal and external insulativeproperties of the wallboard provide a significant advantage over knownbuilding construction walls and wall structures and also provideenhanced modularity and ease of installation.

In addition to the wall section itself, the present invention providesan improved system and method of erecting and assembling a housingstructure using the wall sections described above. This Perfect Slab™and automated alignment system and method begins by providing aplurality of base forms around the boundary of the foundation of abuilding or dwelling. The base forms each comprise an upper runner and alower runner, wherein the upper runner and the lower runner aresupported and interconnected by one or more cross runners. The baseforms are configured to be embedded in a concrete foundation slab forthe building whereby the wall sections disclosed herein are attached tothe base forms in a pre-determined, pre-holed, pre-coded, and/orpre-dimensioned fashion. This greatly simplifies construction andinstallation of a building comprised of the present wall sections byessentially provided the base forms as a template for the eventual wallsections. The method of construction utilizing the base forms and wallsections comprises: providing a building plat defining a boundary forsaid building; pouring one or more foundation footers and providing thefoundation footers around the boundary; providing one or more base formsections around the boundary of the building, at least one of the baseforms disposed on the foundation footers; providing one or more lowerouter frame members of one or more wall sections; attaching the lowerouter frame members to a top runner of each of said base form sectionsby one or more bolts extending from the top runner; pouring concrete onand around the base form sections to form a concrete foundation slab ofthe building, wherein at least a portion of the bolts are exposed abovesaid foundation slab; removing the lower outer frame members from thebase form sections; assembling the one or more wall sections eachincluding a frame comprising in part the lower outer frame member;attaching the assembled wall sections to the exposed bolts such that thebase forms support each of the assembled wall sections; attachingwallboard to the outside of each of the frame sections; and, spraying alayer of concrete over the wallboard. One or more straps that contactopposite base form members can also be utilized to prevent side-by-sidemovement or undesired slippage.

Accordingly, it is an object of the present invention to provide astructurally sound and insulative building construction composite.

It is yet another object of the present invention to provide a buildingconstruction system and method that does not require skilled labors toassemble and construct.

It is yet another object of the present invention to provide a buildingconstruction system and method that incorporates automated alignment ofwall components, wall sections, truss sections, floor sections, and/orframe sections.

It is yet another object of the present invention to provide a buildingconstruction system and method that includes a relatively thick concretelayer provide substantial structural rigidity at a decreased cost.

It is yet another object of the present invention to provide a buildingconstruction system and method that provides internal and externalinsulation without the need for insulation batting or spray insulationapplications.

It is yet another object of the present invention to provide a buildingconstruction system and method that incorporates a unitary wallboardpiece having an outer portion for external insulation and concreteadherence as well as an inset portion received with the frame forinternal insulation.

It is yet another object of the present invention to provide a buildingconstruction system and method that utilizing locking key bolts receivedin frame sections which allow for the rapid assembly of rebar supportsand wire guides to further enhance the speed, accuracy, and quality ofthe building construction system and method.

It is yet another object of the present invention to provide a buildingconstruction system and method that can be assembled more quickly thantypical construction methods, even with the use of unskilled laborers.

It is yet another object of the present invention to provide a systemand method of building construction utilizing base forms that form atemplate around the boundary of the building or dwelling for the supportand installation of one or more exterior or interior wall sections,truss sections, roof sections, and floor sections in accordance with thestructure and function disclosed herein.

In accordance with these and other objects which will become apparenthereinafter, the instant invention will now be described with particularreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded schematic of one embodiment of the buildingconstruction wall section of the present invention.

FIG. 2 is a cross-sectional cutaway view of one embodiment of thebuilding construction wall section of the present invention.

FIG. 3 is a perspective view of one embodiment of the buildingconstruction wall section of the present invention.

FIG. 4 is another perspective view of one embodiment of the wall sectionof the present invention.

FIG. 5 is a perspective view of one aspects of the frame and wallboardconfiguration of the present invention.

FIG. 6 is a perspective view of one embodiment of the wallboard of thepresent invention showing the inset portion, outer portion, andchannels.

FIGS. 7A-7C depict various embodiments of the key bolts and the key holdengagement used with the frame of the present invention.

FIG. 8 is a perspective view of another embodiment of the presentinvention, utilizing support arches useful for concrete application.

FIG. 9 is a schematic of a concrete layer being sprayed onto thewallboard/frame in accordance with the present system and method.

FIG. 10 is a perspective view of one embodiment of one or more base formsection assemblies of the present invention installed onto a foundationfooter.

FIG. 11 is a side view of one embodiment of the fastening structureattaching an outer lower frame member of the wall section to a toprunner of the base form of the present invention.

FIG. 12 is a flow chart depicting one embodiment of the constructionmethod of the present invention utilizing base forms and wall sectionsdescribed herein.

FIG. 12A is a flow chart depicting one embodiment of the constructionmethod of the present invention utilizing roof truss, floor truss andhouse members in conjunction with base forms and wall sections describedherein.

FIG. 13 shows a plurality of foundation footers disposed in the groundin accordance with the building construction method of the presentinvention.

FIG. 14 shows the installation of a plurality of base form sectionaround the boundary of a building plat in accordance with the buildingconstruction method of the present invention.

FIG. 15 shows the use of a side adjustor to level the base form sectionsin accordance with the building construction method of the presentinvention.

FIG. 16 shows the base forms of the present invention supported by rebarsections in accordance with the building construction method of thepresent invention.

FIG. 17 shows a plurality of lower outer frame members of the wallsections attached to the base forms in accordance with the buildingconstruction method of the present invention.

FIG. 18 shows an up close view of a plurality of lower outer framemembers of the wall sections attached to the base forms furtherincluding plumbing features in accordance with the building constructionmethod of the present invention.

FIG. 19 is a top view showing a plurality of lower outer frame membersof the wall sections attached to the base forms further includingplumbing features in accordance with the building construction method ofthe present invention.

FIG. 20 is another view showing the base forms surrounding one or moresupport beams in accordance with the building construction method of thepresent invention.

FIG. 21 shows a plurality base form sections surrounded by a retainingwall sections in preparation for a concrete pour in accordance with thebuilding construction method of the present invention.

FIG. 22 shows a rebar support grid laid on the building plat inpreparation for a concrete pour in accordance with the buildingconstruction method of the present invention.

FIG. 23 shows the concrete foundation slab with the lower outer framemembers exposed for removal in accordance with the building constructionmethod of the present invention.

FIG. 24 shows the concrete foundation slab with the attachment boltsexposed for later installation of wall sections in accordance with thebuilding construction method of the present invention.

FIG. 25 shows a plurality of wall sections attached to the base forms inaccordance with the building construction method of the presentinvention.

FIG. 26 is a cross-sectional view of a concrete foundation slab having abase form section embedded therein with bolts for attachment to the wallframes exposed.

FIG. 27 is a cross-section view of a stem wall foundation configurationhaving a base form of the present invention embedded therein forattachment and support of a frame member of a wall section of thepresent invention.

DETAILED DESCRIPTION

The present invention overcomes the disadvantages of the prior art byincorporating a combination of sprayed concrete onto an internal andexternal insulating board which is cladding a steel stud frame. Withreference to FIG. 1, shown is an exploded schematic of one embodiment ofthe wall section of the present invention arranged and constructed inaccordance with one embodiment of the method of the present invention.Shown is a section, or a portion of a composite construction wallidentified as wall section 1. Wall section 1 comprises a frame 10, awallboard 11, a support grid 12, and a concrete layer 13. The wallsection 1 is provided as a wall structure for a building or housing unitand will typically be assembled in sections as described in detailbelow.

With reference to FIGS. 1 and 2, the wallboard 11 is secured to anddisposed on an exterior side 101 of the frame 10. In some embodiments,wallboard 11 is secured to frame 10 by an adhesive such as an epoxy orclue. In some embodiments, wallboard 11 is further fastened to frame 10by one or more key bolts 30 received through wallboard 11 andterminating within a portion of frame 10. A plurality of bolts 30 may beprovided through wallboard 11 and into frame 10 to provide a secureattachment of the two components. Specifically, the bolts 30 may includeeyelets that are configured to receive and secure rebar support 14and/or guide wire 15 which provide additional support and guidance forthe application of the concrete layer 13, as discussed in further detailbelow. In some embodiments, the key bolts 30 are configured to lockinglyengage pre-fabricated key holes provided in the frame 10 to allow forease of installation, as further described below. However, otherfasteners may be used instead of bolts, such as screws, nails, staples,and the like.

Also provided in some embodiments is the support grid 12 which is spacedapart from but attached to wallboard 11. Grid 12 may comprise a wiremesh grid, a rebar grid, or similar rigid grid that provides additionalstructural support for concrete layer 13. In some embodiments, grid 12is attached to either rebar support 14 or one or more bolts 30 by ties35 which are received around both the grid 12 and either the rebarsupport 14 or a bolt 30. Other means of connecting the grid 12 may beemployed, including brackets, screws, bolts, staples, and the like. Insome embodiments, the wire grid 12 is disposed between the wallboard 11and the guide wire 15 such that the guide wire 15 is on the outside ofthe wall section 1. The rebar support 14 is disposed between thewallboard 11 and the grid 12. Further, it is appreciated that one ormore rebar supports 14 may be provided, with corresponding bolts, andthe rebar supports 14 may be disposed horizontally and/or vertically, orin a frame-like manner around the periphery of the frame 10.

In some embodiments, concrete layer 13 is sprayed over grid 12 such thatthe concrete adheres to wallboard 11 and has a thickness extending awayfrom wallboard 11. Grid 12 and/or rebar 14 provide structural supportfor the adherence of concrete layer 13 to wallboard 11. In someembodiments, concrete layer 13 is applied in multiple thin-layerapplications in order to assure adherence and structural rigidity withrespect to wallboard 11. The guide wire 15 is disposed across thewallboard and may provide guidance during the application of theconcrete layer 13, i.e. to delimit the desired depth of concrete layer13 application. As depicted in FIG. 2, concrete layer 13 is applied suchthat grid 12 and rebar 14 is disposed within the concrete layer 13; or,said differently, concrete layer 13 is disposed on either side of grid12 and/or rebar 14 and, in many cases, will be disposed through grid 12wherein grid 12 includes interstitial gaps 121 (FIG. 1) by way of itsgrid configuration. In some embodiments, it is preferred that concretelayer 13 have a thickness of approximately 2-3 inches extending from thewallboard however the thickness may vary depending on the desiredapplication and building plan. The grid 12 provides support for andcatches the concrete layer 13 during application to prevent the concretefrom sliding down the wall surface. The rebar supports 14 providestructural reinforcement once the concrete layer 13 has set. In FIG. 2,it is appreciated that the guide wire 15 provides a designation of thedepth of concrete layer 13 to be applied. In some embodiments, the guidewire 15 will be flush with the outer edge of the concrete layer 13.However, for illustrative purposes in FIG. 2, the guide wire 15 is shownto be contained inside the concrete layer somewhat—such a configurationis not required nor should the depth of the concrete layer 13 andrelationship to guide wire 15 be limited to that shown in FIG. 2.

In some embodiments, the stud frame 10 of the present invention isconstructed through use of a fabricating machine which forms the studsfrom coiled metal (steel, aluminum, and the like) and marks thecomponents with coding to allow for quick, easily assembled constructionby workers who do not need high level construction skills, rather theyneed only to match the markings for assembly. FIG. 4 shows an example ofone section of frame 10 shown having a generally square or rectangularshape. Shown is frame 10 from the perspective of interior side 102 withwallboard 11 attached to the exterior side of frame 10. Frame 10 mayinclude outer framing members 103 and one or more cross members 104,which functions as studs, providing a riding structural support systemfor building construction.

Wallboard 11 comprises an insulative material and is configured toprovide both external and internal insulation for the constructionsystem in a unitary piece. As shown in FIGS. 1, 2, 4, 5 and 6 wallboard11 is configured as having an outer portion 111 and an inset portion 112wherein the inset portion 112 is configured to be received within theinterior cavities 140 of the frame 10 and the outer portion is disposedon the exterior side of the frame 10. In some embodiments, the insetportion 112 and the outer portion 111 are unitary and integral,constructed homogenously as wallboard 11. The outer portion 111 providesexternal insulation and provides a surface for the concrete layer 13 toadhere to. The inset portion 112 provides internal insulation and addsrigidity to construction wall section 1 once assembled. In someembodiments, the inset portion 112 is deeper than the outer portion 111,for example the inset portion 112 may have a depth of 2 inches extendinginto the frame 10 whereas the outer portion 111 has a depth of 1 inchextending outward from the frame 10. In some embodiments, the perimeterof the outer portion 111 is larger than the perimeter of the insertportion 112.

In some embodiments, the inset portion 112 includes one or more channels113 which are configured to accommodate the cross members 104 of theframe 10. This allows the inset portion 112 wallboard 11 to fit snuglyand securely within the internal cavities 140 of frame 10 with minimalmovement, which eases construction and assembly and provides addedrigidity and stability to the construction wall section 1. FIG. 5demonstrates the configuration of the outer portion 111 and insetportion 112 of wallboard 11 as well as the fitment of same inside theinternal cavities 140 of frame 10 by way of channels 113. FIG. 6 showsthe wallboard 11 along, with outer portion 111, inset portion 112, andchannels 113. It is appreciated that the relative thickness of outerportion 111 and inset portion 112 can vary depending on the desiredapplication and desire structural and insulative properties. Further,the configuration, size, and shape of the channels 113 can varydepending on the configuration of frame 10. Accordingly, the presentinvention is not limited to the configurations shown in the figures.

In some embodiments, the framing members 103 and 104 include one or moreapertures 105 punched there-through. The apertures 105 are configured toreceive and channel electrical wiring, plumbing, and the like. In someembodiments, conduits 106 are provided through apertures 105 and provideprotection for wiring or plumbing passed there-through. As shown in FIG.4, in some embodiments the inset portion 112 of wallboard 11 has a depththat accommodate and does not block apertures 105 and conduits 106,which conduits are adjacent to the inside surface of the wallboard 11.In other embodiments, it may be desired for the depth of inset portion112 to be somewhat deeper where it would otherwise cover up or block theapertures 105. However, in this case, additional channels 113 can beprovided which align with apertures 105 and therefore accommodateconduits 106 similar to how the channels 113 accommodate the crossmembers 104 of frame 10.

In some embodiments, the inside of the frame 10 at interior side 102 offrame 10 may receive and contain insulation material 107 which may bepoured, sprayed, or applied in sheets or rolls thereto. In someembodiments, the insulation will be applied to the back of inset portion112 of the wallboard 11, which is disposed within the frame 10. However,insulation material 107 may not be necessary in situations and climateswhere the wallboard 11 with inset portion 112 provides sufficientinsulation. Accordingly, the material selected for wallboard 11 may varydepending on desired insulative characteristics as further discussedbelow. Additionally, the depth of inset portion 112 of wallboard 11 canbe increased in order to increase its ability to insulate, depending onthe desired application and installation.

It is further appreciated that the interior side 102 of frame 10 istypically the side facing the inside of the particular building or homeand the exterior side 101 (which receives wallboard 11, grid 12, andcement layer 13) is the exterior of the building or home. The interiorside 102 may be finished with typical interior wall material such asdrywall, plasterboard, sheet rock, and the like.

The result of the present invention is a combined building or housingframe 10 structure covered with an insulating exterior wallboard 11 towhich a sprayed concrete layer 13 has been applied. Each frame 10 asdescribed above comprises at least a portion of a wall of a building orhousing structure. This configuration provides substantial strength anddurability and exceeds typical hurricane, earthquake, tornado and otherweather strength rating requirements presently used throughout theworld. This enhanced strength is achieved primarily due to therelatively thick concrete layer 13 combined with the rigid frame 10 andfurther combined with the extended-depth wallboard 11 which provideinternal insulation at the frame. In accordance with the presentinvention, a housing unit can be assembled in a matter of three or fourdays rather than months by utilizing the building construction systemand method and automated alignment of the present invention; minimalskill is needed by the assembly crews and fabrication can be customizedto meet local codes, plumbing and electrical requirements. Most singlefamily units are anticipated to be in the twelve hundred to fifteenhundred square feet of living space. The units can be built asindependent units or in multiple family configurations and, in thatsense, the particular size and configuration of a given housing unitbuilt in accordance with the present invention is not limiting.

To further enhance the ease of assembly of the construction wall section1 of the present invention, the frame 10 is configured to lockinglyreceive a plurality of bolts 30 having various configurations. In someembodiments, the bolts 30 are received in flanges of the frame 10 atvarious points along the frame 10 as desired for the particularapplication. With reference back to FIG. 1, shown are two sets of bolts30 wherein the first set is configured to receive and retain a rebarsupport 14 and a second set is configured to receive and retain a guidewire 15.

With reference to FIGS. 7A-7C, shown are various embodiments keyhole/key bolt 30 configuration of the present invention. FIG. 7A depictsone embodiment of a key bolt 30 configured as a stud screed bolt. Theproximal end of the bolt 30 includes a bow-tie or bubble-like maleconnector 31 and the distal end includes a receiving eyelet 32. A boltflange 33 may be provided proximal to the male connector 31. In thisembodiment, the receiving eyelet 32 is relatively small and isconfigured to receive guide wire 15. FIG. 7B depicts another embodimentof a key bolt 30 configured as a support bolt. The proximal end includesa bow-tie or bubble-like male connector 31 and the distal end includes areceiving eyelet 32. Again, a bolt flange 33 may be provided proximal tothe male connector 31. In this embodiment, the eyelet 32 is somewhatlarger and is configured to receive and engage a rebar support 14.

As shown in FIG. 7C, frame 10 may include one or more flanges 301 whichmay comprise stamped or bent portions of the frame 10. One or more keyholes 302 are provided through flanges 301 and provide a point of entryfor the male connector 31 of key bolts 30. In some embodiments, a keybolt 30 passes through wallboard 11 and into the key hole 31 of frame 10and is then rotated 90 degrees such that the male connector is lockinglyengaged with the flange 301 of frame 10. The key hole 302—key bolt 30arrangement provides a simple and easy to operate means of attachingrebar and guide wire to the frame 10, which provides added support andconcrete application guidance for the construction wall section 1. It isappreciated that the key holes 302 could be provided anywhere on theframe 10 and do not necessarily have to be on the flange 301. Further,with reference back to FIGS. 1-4, it is appreciated that two or more keybolts can be used in conjunction to support a rebar support 14 and/or aguide wire 15. In some embodiments, the key holes 302 are provided atequidistant points along the frame 10 and the key bolts 30 are providedtherein such that the weight of the rebar 14 and/or guide wire 15 can beequally supported along the frame.

It is further appreciated that, in some embodiments, the length of thekey bolts 30 utilized for the guide wire 15 are substantially longerthan the length of the key bolts 30 used support the rebar 14. Thisconfiguration allows the guide wire 15 to extend well beyond thewallboard 11 surface in order to delineate the maximum depth orthickness of concrete layer 13 to be applied. Accordingly, a variety ofvarying length key bolt 30 for guide wire 15 can be utilized to providea guide for various desired depths of the concrete layer 13.

The wall configuration, square footages, windows, doors, electrical,plumbing, ventilation and other requirements are placed into a take offfor analyses by a computer software program for calculation of number offeet needed for frames 10, frame 10 dimensions and placement, cut outsfor placement of plumbing and electrical wires, placement of windows,doors and ventilation needs, as well as sizing to meet local andnational codes and best practices for the location where the homes aregoing to be built. The result of the multi-stage analyses is acomputerized output of frame 10 requirements that can be fed into aframe fabricating machine. The frame fabricating machine then canproduce the frames 10 in sections, including the cross-members and outermembers needed for the construction of the unit. The frames aretypically fabricated from rolled coils of sheet metal material such assteel or aluminum but may also comprise wood or other materials assuitable for the particular application. In some embodiments, a steelframe section having a 3-inch concrete layer applied thereto is capableof withstanding at least 50,000 psi of pressure and therefore ispreferred as a weather-rated material in certain applications. As theentire frame structure is fabricated typically in discrete sections, theframe sections are marked at each end with a coding number. Headers andsills are likewise marked with numbers at all locations where they willinteract with the frame sections or any bracing pieces, cross-members,and the like. Typically, the frame 10 sections are produced in the orderof assembly, so that the pieces are assembled in the order offabrication.

The present invention also comprises an enhanced and improved system andmethod for constructing a building comprised of the wall sections 1described above. This system and method provides a means to quickly andeasily construct a building in accordance with a pre-determined buildingplan without the need for skilled laborers or the machinery and timeassociated with traditional tilt-up wall or block construction methodsknown in the art. In its basic form, FIG. 10 shows a perspective view ofa base form 200 configured as a frame that is intended to be disposedaround the outer perimeter of a building in multiple sections. The baseforms provide a supporting template for the wall sections 1 as furtherdescribed. As shown, base form 200 comprises an upper runner 201 and alower runner 202 supported and interconnected by one or more crossrunners 203, thus delimiting a frame-like structure. In someembodiments, the base form 200 comprises 16-22 ga steel, although othermaterials and material strengths may be utilized. In some embodiments ofthe system and method, one or more sections of base form 200 aredisposed onto a foundation footer 300. Further, in some embodiments, avertical support beam 400 may be disposed between one or more base form200. A gap 205 may be provided in the base form 200 or two spaced apartbut separate base forms 200 may be provided to accommodate support beam400.

As will be described in greater detail below, base form 200 serves asboth a support structure and a template for automated alignment and theconstruction of a building comprised of a plurality of the wall sections1 of the present invention. Accordingly, the base form 200 is configuredto engage, retain, and support a wall section 1 and, in particular, isconfigured to engage a bottom outer frame member 103′ of a wall section1 as shown in FIG. 10. In some embodiments, a bottom outer frame member103′ of a wall section 1 is attached to the upper runner 201 of the baseform 200 by one or more bolts 204. The engagement of the bottom outerframe member 103′ and the upper runner 201 is shown in FIG. 11. Here,bolt 204 passes through both the upper runner 201 and the lower outerframe member 103′. A first nut 206 is secured at the top surface of theupper runner 201, a second nut 207 is secured at the bottom surface ofthe bottom outer frame member 103′ and a third nut 208 is secured at thetop surface of bottom outer frame member 103′. In some embodiments, thebolts 204 pass through pre-drilled bolt alignment holes 209 disposedthrough the bottom outer frame member 103′.

Constructing a dwelling utilizing the base forms 200 and a plurality ofwall sections 1 is accomplished in a simple, step-wise fashion,constituting automated construction and automated alignment of variouswall sections, roof truss sections, floor truss sections and componentsthereof. Initially, the base forms 200 are dimensioned according to theboundary measurements of a given dwelling's foundation footprint. Insome embodiments, the base forms 200 are selected and stamped out insections that can be easily secured to the foundation footers and othersupporting structure of a dwelling around the boundary thereof. Once thebase forms 200 are secured to the foundation, concrete is applied toresultant foundation such that a slab is formed with the base forms 200extended at least partially above the slab, therefore delimiting theinitial portion of the walls of the dwelling. In some embodiments, thebase forms 200 extend above the foundation slab of the dwelling by1′-3′. Then, the wall sections 1 are attached to the base forms 200 tocreate the outer walls of the dwelling. As such, the base forms 200 aresecured to the foundation to create a “template” for the wall sections1, greatly reducing the time, cost, and complications associated withstandard building construction methods and system.

This building construction methodology is shown and described in moredetail in FIGS. 12 and 12A. First, the building or dwelling plat is laidout and the earth is cleared and flattened for the construction of thebuilding's foundation. Next, one or more foundation footers 300 arepoured and disposed into the ground at strategic locations around theboundary of the eventual building, as shown in FIG. 13. The footers 300are then covered with earth in the traditional manner and the plat isleveled. Next, one or more base form 200 sections are brought to the jobsite and are attached to the footers 300 as shown in FIG. 10. The baseform 200 sections are placed around the boundary of the building asshown in FIG. 14. In some embodiments, one or more side adjustors 500are attached at various points along the base form 200 sections to actas levelers for the base forms as shown in FIG. 15. The side adjustors500 temporarily support the base form 200 sections at the lower runner202 thereof and are height adjustable in order to adjust and eventuallylevel each of the base form 200 sections to one another and thefoundation. Once the base form 200 sections are leveled, one or morerebar supports 501 are provided through the lower runners 202 of thebase form 200 sections at intermittent locations thereof (See FIGS.15&16). In some embodiments, the rebar supports 501 are equally spacedthrough the base form 200 sections at, for example, 2 feet increments.FIG. 16 shows and exemplary embodiment of the base form 200 sectionseach having a rebar support 501 disposed through the lower runners 202thereof. If desired, lateral straps can be utilized to connect toopposite base form sections 200 to prevent side-by-side movement,lateral movement, undesired slippage, rotation or angular displacementof these sections, as well as roof truss sections, floor truss sections,wall sections or the like.

After the base form 200 sections are leveled and stabilized with therebar supports 501, the wall sections 1 can start to be secured to thebase form 200 sections. It is appreciated that the building will becomprised of a plurality of wall sections 1 having varying dimensionsaccording to the requirements of the building plan. For example, wallsections 1 may be provided in various widths such as 10 feet, 8 feet, 7feet, and the like provided they are dimensioned to meet therequirements of the building boundary and the construction plan. Withthat in mind, in some embodiments, the lower outer frame members 103′ ofeach wall section 1 are brought to the job site and aligned with theircorresponding base form 200 sections along the boundary of the building.The alignment holes 209 of the frame members 103′ are aligned with thebase form 200 top runners 201 and corresponding alignment holes aredrilled or punched through the top runners 201 of each base form 200section. Next, the bottom frame members 103′ are attached to the baseforms by the nut and bolt configuration shown in FIG. 11. FIG. 17 showsthe base form 200 sections with attached outer lower frame members 103′.FIG. 18 shows the base form 200 sections with outer lower frame members103′ wherein one or more plumbing features 600 are provided through thebase form 200 sections and the members 103′. In this manner, plumbingand electrical can be placed throughout the foundation structure in aneasy and efficient manner prior to placing the walls or pouring thefinal foundation slab. FIG. 19 is a top perspective view sowing theframe members 103′ attached to the base form 200 sections by the one ormore bolts 204. Also shown are the plumbing features 600. As shown inFIG. 10, the base form 200 sections may be supported by one or morebeams 400. FIG. 20 shows a plurality of the support beams 400 at variouslocations around the boundary of the plate disposed between base form200 sections.

Next, with the outer lower frame members 103′ in place and attached tothe base form 200 sections, foundation rebar support grid 700 is placedinside the boundary of the foundation and concrete is poured onto theentire foundation structure to form a final concrete foundation slab800. To assist in retaining the concrete during pouring, one or morepermanent or temporary retention wall sections 900 can be disposedand/or attached to the outside of the base form 200 sections as shown inFIG. 21. FIG. 22 shows the rebar support grid 700 and FIG. 23 shows anexemplary final concrete foundation slab 800 after concrete is poured tofill the plat. The concrete is poured onto and through the base form 200sections and is then smoothed and leveled to an elevation at leastreaching the top runner 201 of the base form 200 sections. This leavesthe lower outer frame members 103′ of the wall sections 1 and the bolts204 exposed for further construction as described below.

Next, the concrete is permitted to cure and then the exposed outer lowerframe members 103′ are removed from the base form 200 sections with thebolts 204 left in place in the top runners 201 of the base form 200sections. FIG. 24 shows the exposed bolts 204 with concrete surroundingand covering the base form 200 sections. The frame members 103′ are thenattached (or reattached) to their corresponding frame 10 of wall section1. The assembled frames 10 are then brought to the job site (afterconcrete foundation slab is cured) and are each reattached to thecorresponding bolts 204 exposed above the base form 200 sections asshown in FIG. 25. As shown in FIG. 26, in some embodiments, the concretefoundation 800 is poured to an elevation above the base form 200sections such that the sections are completely encased within thefoundation slab 800. As referenced above, lateral straps can be utilizedto connect to opposite base form sections 200 to prevent lateralmovement, undesired slippage, rotation, or displacement of thesesections in assembly, and while the concrete foundation is poured,sprayed and/or cures. The surface of the concrete foundation slab 800 isstepped where 801 points in order to accommodate the lower outer framemember 103′ which is generally not covered in concrete when installedonto the base form 200 sections. The step 801 is also shown in FIG. 24.This step leaves room for the installation of the frames 10 and isdimensioned specifically to receive the lower outer frame member 103′ ofeach frame 10. Here, the bolts 204 extend upward and are exposed toprovide a mounting point for the frame members 103′. In someembodiments, such as that shown in FIG. 27, the base form 200 sectionmay be disposed in a stem wall foundation 802 section forming a part ofthe concrete foundation slab 800. Again, the depth of the concrete ispoured such that the bolts 204 extend above the concrete surface withsufficient depth to accommodate the lower outer frame member 103′ of agiven frame 10 of a wall section 1.

Once the frames 10 are in place on the base forms 200, interior wallsand trusses are attached. The automated alignment system is utilizedsuch that the bottom portion of a truss section and top portion of awall section are attached with pre-determined bolt holes where the trussis placed accurately and properly spaced without the need for fieldmeasurements or assembly of components. Wallboard 11 is attached to thenow completed and attached frames 10 and the wall sections areconstructed in the manner described above substantially as shown inFIGS. 1-9. Thus, the exterior sides 101 of frames 10 are covered withthe wallboard 11, therefore providing internal and external insulatingproperties, which inset portion 112 of the wallboard 11 is received inthe cavities 140 of the frame 10. The wallboard 11 may be secured to theframe 10 by an adhesive, epoxy, or the like. The wallboard may befurther affixed to the frame 10 sections with fasteners and/or, in someembodiments, key bolts 30 may be provided through the wallboardtherefore providing two purposes (1) provide additional fastening of thewallboard 11 to the frame and (2) provide a means to attach rebar 14and/or guide wire 15 to the assembly. If rebar supports 14 are desired,the supports are provided into the eyelets of the one or more key bolts30. Grid 12 may be then fastened to the bolts 30 or the rebar 14 by wireties 35, whereby the grid 12 helps with the application of concretelayer 13 and adds tensile strength to the concrete layer 13. If a guidewire 15 is desired, it is secured through the eyelets of one or more keybolts and thus the guide wire 15 may define the depth of concrete layer13 to be applied over the wallboard 11. It is appreciated the wallboard11 is configured with channels 113 that match the configuration of theframe 10, including any cross members 104 and conduits 106 as desired.

The concrete layer 13, in some embodiments, is applied by a sprayingapplication and depicted in FIG. 9. Multiple thin layers of concrete maybe applied until the concrete layer 13 has a suitable thickness, forexample 2-3 inches. In some embodiments, the guide wire 15 designatesthe depth of the concrete application. It is desirable for the grid 12and the rebar 14 to be located substantially in the middle of theconcrete layer and thus the grid 12 and rebar 14 are spaced apart fromthe wallboard 11 and the final outer wall surface of the concrete layer13. Once the concrete layer 13 has cured, the housing structure isformed and finishing can take place. Roof frame 10 sections may beconstructed in a similar manner but would typically be covered with aroofing material of choice as wallboard 11, preferably a material thatprovides good water resistance and good insulation.

With reference to FIG. 8, to further assist in the concrete layer 13application and particularly with respect to multiple story or multiplelevel applications, one or more support arches 70 may be secured to oneor more bolts 30. The arches 70 may comprise strips of metal or otherrigid material and have a width that extends outwardly from the surfaceof the wallboard 11. The arches 70 may be disposed between the wallboard11 and the wire grid 12 and are provided in order to catch the concretelayer 13 during the spraying application. The geometry and location ofthe arches 70 is not limited, and other similar strips may be providedon the wallboard 11 to effectuate this purpose.

The wallboard 11 may comprise a variety of building constructionmaterials known in the art and is particularly useful because itprovides both external and internal insulation in a single, easy toinstall piece. In some embodiments, the wallboard 11 comprises asuitable expanded polystyrene material providing insulative properties.In some embodiments, the wallboard 11 comprises what is known in the artas “blueboard” which is configured to accept and react with the cementlayer 13 for optimal adhesion and durability. Other foam-like materialsmay be utilized as wallboard 11 and such materials may be chemicallytreated to accept adherence of cement. As is known in the art,“blueboard” is typically a foam-board insulation material comprisingpolyisocyanurate, extruded polystyrene, expanded polystyrene foam, andcombinations thereof. The wallboard 11 material may be selectedaccording to its “R-value” or thermal resistance value and maypreferably have an R-value between 4.5 and 5.0, which is typical ofblueboard known in the art. However, in some embodiments the wallboard11 comprises primarily expanded polystyrene which may have an R value of12 or greater, depending on the overall thickness. Such an R-valueprovides a significant improvement over typical construction methods. Itis appreciated, that other materials including composite styrofoam, foamand foam-like boards known in the art are contemplated, provided theyhave improved insulation, strength, and plaster/cement adherencecharacteristics. In any event, it is appreciate that the presentinvention provides a significant advantage over the prior art becausethe wallboard 11 provides both internal and external insulation as wellas providing a surface for the concrete layer 13 to adhere to.

The application of the concrete layer 13 is quickest and most efficientwhen sprayed, as shown in FIG. 9. The concrete mix can be customizedwith additives to get better adherence to the wallboard 11 and can beadjusted as to drying time. Further use of elastomeric additives to theconcrete reduces cracking of the concrete surface, and helps in creatinga watertight envelope. The thickness of the concrete is a function ofthe strength desired and for commercial type installation it may beincreased.

As mentioned above, interior walls can be covered with typical drywallmaterials and if additional insulation is desired it can accomplished byusing blown in insulation, batting, or board type, installed on theinterior side 102 of the frame 10. However, additional insulation is notnecessary in most instances because of the substantial external andinternal insulative properties of the extended wallboard 11. Theexterior concrete, after curing, can be painted or finished with afinishing material such as stucco to provide the desired appearance.When constructing multiple identical units, the product can be quicklyassembled and made ready for use. The method of construction of theunits consists of fabricating the frames, marking the frames, assemblingthe frames in the walls, trusses and assemblies, covering the exteriorwalls with the wall board, adding the grid to the exterior surface ofthe wall board; spraying the exterior with wall board with the desiredamount of cement; allowing the concrete to cure. By following thesesteps a very strong structure for an affordable quickly built housing orcommercial units is obtained.

The combined concrete, with board and frame structure creates acomposite structure with unexpected strong properties to resistearthquake, hurricane, tornado and other disruptive effects as well asprovide incredible internal and external insulative properties for thegiven weight and cost of the materials. The final product has superiorstrength for a housing unit that can be quickly and economicallyconstructed with a labor for having minimal skill sets. There arenumerous variations that can be employed with respect to the materialsselected in order to meet the local conditions and to accommodate theneed being addressed.

The automated building construction methods and automated alignment ofcomponents as described herein are to be distinguished from conventionalbuilding construction in several distinct ways. Stick Framing is a handbuilt framing, with either wood or steel studs and is a slow process,components which are not square or accurately cut and manually assembledat the job site. Conventional construction involves taking all theframing and trusses to a job site, and the house is framed and builtthereafter. All walls are field measured and trusses attached usingstring line or filed laser techniques attempting to achieve properalignment. This is an inefficient and slow process which invariablyresults in numerous errors.

The instant automated framing is a frame that's accurately cut within1/16 of inch for the exact wall and for a precise location of the housebeing constructed. This wall framing is exported from a CAD blue pint ofthe house. The process is fast, inherently accurate, maintains propersquared sections and is extremely cost effective.

In one aspect of the automated method, a bottom cord truss has a hole 18inches in from the heal or end of the truss. The exterior receiving wallwhere the truss is to be placed has a dowel bolt protruding from thecenter of the wall in the exact location where the truss needs to bereceived. The slab takes the peripheral dimensions of the house, forexample with an offset by 8 inches (3 inches for the concrete and 1 inchfor the foam×2, for each side of house, =8 inches).

As a further example, a house back of house is 25 feet 5½ inches. Theinstant slab generic box is made at 25′5½″, and the side adjustors areadded (used for leveling). The walls that are going to be placed on thishouse section consist of 3 walls W1, W2, and W3. These bottom plates ofthese walls are placed on the top of the slab box which is used as atemplate for the placement of the bolts for wall attachment to theconcrete slab. All bolt holes are then drilled into the top of the slabfor perfect alignment. Thereafter, a 6 inch bolt is placed into a hole,and is attached by a nut. Then another nut is placed 4½ inches apart.The receiving wall W1 bottom base plate is then positioned on top of the4½ inch bolt, nut and washer. At this point another washer and nut isscrewed on top of the bolt to firmly lock in the W1 bottom base plate.This W1 base plate is left in place until the slab hardens. The W1 baseplate is then removed from slab. The W1 bottom base plate is thereafterattached to the whole W1 frame wall at a factory or assembly locationremote from the job site. This completed W1 wall frame is thereafterdelivered to the job site and the entire wall frame assembly is attachedin exactly the correct location on the slab, because of the inherentlyaccurate automated alignment system described and claimed herein. Thesame process is utilized with respect to the roof truss, floor truss andinterior wall sections as desired.

In some embodiments, the frame, wall, floor, roof and truss sections aremanufactured using a computer software system that pre-fabricates thehole or code placement into top tracks for easy assembly and inherentalignment of sections as described herein.

The instant invention has been shown and described herein in what isconsidered to be the most practical and preferred embodiments. It isrecognized, however, that departures may be made therefrom within thescope of the invention and that obvious modifications will occur to aperson skilled in the art.

What is claimed is:
 1. A composite building construction system,comprising: a base form comprising an upper runner, a lower runner, saidupper runner and said lower runner supported and interconnected by oneor more cross runners; a wall section comprising a frame, a wallboard,and a concrete layer wherein said wallboard is attached to an outer sideof said frame, said wallboard providing exterior and interior insulationfor said system, wherein said concrete layer is provided on said outerportion of said wallboard; wherein said base form supported by afoundation footer; wherein said upper runner of said base form isconfigured to receive and support a lower outer frame member of saidframe of said wall section; and wherein said base form comprises atleast a portion of a support structure that supports said wall section.2. The composite building construction system of claim 1, furthercomprising one or more rebar supports attached to said frame at saidexterior side of said frame.
 3. The composite building structure ofclaim 2, wherein said rebar supports are secured to one or more keybolts lockingly engaged with said frame.
 4. The composite buildingconstruction system of claim 3, further comprising a wire grid attachedto said one or more key bolts and spaced apart from said wallboard, saidgrid and said rebar supports supporting said concrete layer.
 5. Thecomposite building construction system of claim 1, wherein said concretelayer has a thickness of 3 inches.
 6. The composite buildingconstruction system of claim 1, wherein lower outer frame memberincludes one or more holes configured to receive a bolt, said boltreceived through said lower outer frame member and said top runner ofsame base form to secure said frame member to said base form.
 7. Thecomposite building construction system of claim 1, further comprisingone or more guide wires attached to said frame by key bolts at saidexterior side of said frame, said guide wires spaced apart from saidunitary wallboard and adapted to indicate the depth of said concretelayer.
 8. The composite building construction system of claim 1 whereinsaid frame member is prefabricated and coded for assembly.
 9. Thecomposite building construction system of claim 1, wherein an interiorside of said frame is configured to receive drywall.
 10. The compositebuilding construction system of claim 1, wherein said frame comprisessteel.
 11. A compositing building construction system, comprising: aplurality of base form sections disposed around the boundary of abuilding plat, each of said base form sections including an upper runnerand a lower runner, said upper runner and said lower runner unconnectedby one or more cross runners; a plurality of wall sections, each of saidwall sections comprising a frame having a lower outer frame member;wherein said base form supported by a foundation footer of said buildingplat; and wherein said upper runner of said base form is configured toreceived and support said lower outer frame member of a correspondingwall section in automated alignment.